multi-physics and non-linear modeling using comsol
TRANSCRIPT
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
1/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
Multi-physics and nn-linear mdeling using!"MS"#
Venkat Perumal
Siemens ec!nolo"# an$ Ser%ices Pri%ate Limite$
&esearc! an$ ec!nolo"# Center, ' (0, )eonics, *lectronics Cit#
+an"alore 50100, n$ia
%enkates.aran/siemens/com
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
2/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
$ntrductin
!e ke#note resentation .ill co%er t!e follo.in" toics
Mo$elin" of riction Stir el$in" 4S rocess
6on-linear mo$elin" of ol#meric structure
7lication buil$in" for comosite structures
Pa"e 2
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
3/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
%S& descriptin
%rictin Stir &elding '%S&( is relatively advanced
metal )ining technlgy *r+s in the slid state
,int types
S is .i$el# accete$ 8oinin" rocess for aluminum, ma"nesium, titanium allo#s
Pin
Shoulder
el$in" b# frictional an$ lastic%iscous $issiation
S!oul$er: ;enerate frictional !eat an$ re%ents material
e3
Pa"e 3
http://www.twi-global.com/http://www.twi-global.com/
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
4/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
ma"e courtes#: 1/ .../siemens/com , 2/ .../t.i-"lobal/com
%S& inds applicatin in several industries due t
its technlgical advancements ver the
cnventinal prcesses
Pa"e >
7erosace1 Mobilit#1
S!i buil$in"2 *ner"#1
http://www.twi-global.com/technical-knowledge/published-papers/nz-fabricators-begin-to-use-friction-stir-welding-to-produce-aluminium-components-and-panels-august-2006/http://www.twi-global.com/technical-knowledge/published-papers/nz-fabricators-begin-to-use-friction-stir-welding-to-produce-aluminium-components-and-panels-august-2006/
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
5/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
eat generatin due t the pin and shulder
.../comsol/com
P/ Cole"ro%e et al/, Procee$in"s of t!e 2n$ nternational S#mosium on riction Stir el$in", ;ot!enbur", S.e$en, 2000
eat generatin in %S& is gverned y the rictin
et*een the shulder and *r+piece and the
*r+piece plasticity
Pa"e 5
eat generatin due t shulder 'q shoulder (
eat generatin due t pin tl 'q pin(
qshoulder q pin
? @eat "eneration $ue to t!e friction bet.een
t!e s!oul$er an$ t!e .orkiece is function of
t!e
µ- friction coefficient
n A for"e force 4from e
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
6/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
emperature dependant yield strength the
allys is an imprtant input mdel
Pa"e
0
20
40
60
80
100
120
140160
180
125 130
167
Thermal conductivity (W/m-k
!hemical cmpsitin '*t .( aluminum allys1
Al !u Mg !r %e Mn Si i n 3esiduals
AA4041 95/(-9(/ 0/15-0/> 0/(-1/2 0/0>-0/35 0/0D0 0/002 0/>-0/( 0/0015 0/0025 0/15
AA556 9>/2-9D 0/10 2/-3/ 0/0003 0/00> 0/005 0/00> 0/0015 0/002 0/15
AA05 (D/1-91/> 1/2-2 2/1-2/9 0/1(-0/2( 0/005 0/003 0/00> 0/0020 5/1-/1
Variation of #iel$ stren"t! .it! temerature2 !ermal con$ucti%it# of t!e allo#s
1/ !tt:.../mat.eb/com2/ Perumal, V/42010/ Dissimilar Metal Friction Stir Welding of Aluminum to Magnesium Alloys. 4=octoral $issertation/ &etrie%e$ from
!tt:sc!olarcommons/sc/e$uet$22>3
2D5 3D5 >D5 5D5 ,D5 DD5 (D5
0
50
100
150
200
250
300
!!6061
-T6
emerature 4)
Eiel$ stren"t! 4MPa
http://www.matweb.com/http://www.matweb.com/
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
7/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
The backing plate efect was simulated bythe appropriate convective heat transercoe!cient "h#
The "ackin# $late e%ect &a' 'imulated "y the a$$ro$riate convective heat tran'ercoe)cient (h to 'ave the com$utational time
1
2
2 B 3
2 B 3
>
2
1
1 Constant temerature
2 Con%ecti%e surface
3 &a$iation
> Outflo.
qshoulder q pin
5 5
5 @eat source
Pa"e D
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
8/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
! linear i'otro$ic hardenin# model i' u'ed to model the lar#e 'train$la'ticity
$lasto%plastic behavior coupling o theworkiece with thermal to address the multi%physics nature o &'(
Pa"e (
σ#s0 is t!e initial #iel$ stress, an$
k is t!e isotroic !ar$enin"
mo$ulus/
7 %alue for *tiso isotroic tan"ent
mo$ulus section for in t!e
lasticit# re"ion
!tts:.../comsol/co/in
*lasto lastic be!a%ior of t!e .orkiece
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
9/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
!n auto me'hin# o$tion &a' u'ed to me'h the #eometry* +ackin# $late i'
e,cluded to reduce the com$utational time ho&ever taken care "y the heattran'er coe)cient
$lements around the tool)workpieceinterace are smaller than rest o theworkpiece
Pa"e 9
.lementty$e
o* oelement'
Tetrahedral 4821
Trian#ular 100
.d#e 84
3erte, 8
uality 0*0
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
10/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
'hear layer around the pin tool has beenmodeled to represent the typical highstrain rate in &'(
5n the 'tickin# condition the velocitycom$onent vector'
in'ide the 'hear layer are #iven a' unction o thei tan#ential velocity cau'ed "y the rotational
motion ii tran'lational velocity o the material in ,
direction1
10
&hereu -, com$onent o velocityv- y com$onent o velocity
ω-an#ular velocity o tool in (rad/'
uweld - &eldin# velocity (mm/' - ram$in# actor or the 'hear layer Strain rate and e%ective 'train rate can "e
e,$re''ed a' ollo&'
7elcity and strain cmpnents
S!ear la#er aroun$ t!e in2
Velocit# insi$e t!e s!ear la#er aroun$ t!e in: Source: Sc!mi$t, @ et al/,
Mo$ellin" an$ Simulation in Materials Science an$ *n"ineerin", Vol/ 12,
200>, / 1>3 A 15D/
19 :*+* Schmidt ;* :attel Science and Technolo#y o Weldin# and ;oinin# 3ol
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
11/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
&'( simulation set up used or **6061+ ,nitialparameters have been arrived based on someprior data
Gemetric dimensins r therm-mechanical analysis.
ool in uer $iameter 10/32 mm
ool in lo.er $iameter /3( mm
ool in !ei"!t 2/>0 mm
ool s!oul$er $iameter 25/>0 mm
Plate siFe 150 mm
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
12/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
-esults and discussion
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
13/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
The weld surace with ree rom .ash wasobtained at optimal heat input conditions
5ma#e o a !!6061 "utt &eld Eoint ater 800 r$m 20 mm/min eed
rate
Pa"e 13
=irection of tool tra%erse
Bn'ucce''ul &eld' at lo&r$m and hi#h eed rate'
.*#* == r$m and F10mm/min
eed rate'
Bn'ucce''ul &eld' at hi#hr$m
level' re#ardle'' o theeed
rate
5ma#e o a !!6061 "utt &eld Eoint ater == r$m 0 mm/min eedrate("ottom ri#ht
The &eld 'urace 'ho&' im$ro$er (lo& heatin$ut at == r$m and 0 mm/min re'ultin# in
Gno &eldH ormation
*
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
14/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, PunePa"e 1>
$sthermal temperature cnturs sh* pea+
temperature inside the *eld nugget
AA 4041 ally8 900 3:M and 20 mm/min
emerature isot!erm of t!e 7l late emerature at t!e cross section
COMSOL Conference, 29-30 October, 2015, Pune
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
15/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
The calibration o the model was perormed usingthermocouple measurements at the /*
Side Parameter' .,$erimental Tem$erature (C
Simulation Tem$erature (C
I .rror
!dvancin# 1100 r$m 0mm/min
64 628 0*4
Jetreatin# 616 61= 0*16
!e ma
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
16/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
id plane o the nugget remains hot and lesshot at distances ahead o the tool
Pa"e 1
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
17/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
The increment in the weld nuggettemperature is proportional with thestrain rate
1D
Strain rate i' o"tained or di%erent toolrotational '$eed' =00 to 800 r$mK thetool traver'e '$eed &a' ke$t con'tanto 1= mm/min*
5t i' o"'erved that the e%ective 'trainrate increa'e' &ith increa'e in the toolrotational velocity*
Strain rate i' o"tained or di%erent&eld '$eed' o 101=060120mm/min and the tool rotational '$eed&a' ke$t con'tant o 800r$m*
The 'train rate decrea'e' a' thetraver'e '$eed increa'e'*
500 ,00 D00 (00 900>0
50
,0
D0
(0
300
>00
500
,00
D00
(00
900
Strain rate 41semerature 4)
ool rotational see$ 4rm
Strain rate 41s
emerature 4)
10 20 30 40 50 60 70 80 90
90
92
94
96
98
100
102
Strain rate (1/s)
Temperature (K)
Tool traverse speed (mm/min)
Strain rate (1/s)
Temperature (K)
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
18/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
The nu##et tem$erature o the !!==4 alloy i' the hi#he't com$ared to that o the !! 6061
and !! 0= alloy' &hich can "e attri"uted to the yield 'tren#th and thermal conductivitydi%erence'*
**575 alloy showed highest nuggettemperature than **6061 and 7075 alloys due toyield strength diferences
Pa"e 1(
-100 -80 -60 -40 -20 0 20 40 60 80 100400
=00
600
00
800
!! ==4!! 6061
!! 0=
4istance rom the weld center "mm#
Temperature "#
!dv* 'ide Jet* 'ide
!! ==4 8=1 84
!! 0= 44 4
!! 6061 0 2
!dv* 'ide Jet* 'ide
!! ==4 0= 682!! 0= 60 612
!! 6061 628 61=
6u""et temerature
@7H temerature
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
19/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
,n aluminum alloys the heat generation isgovernedby both the .ow stress and thermal conductivity
The rotational velocity o the tool&a'
'&e$t rom lo& to hi#h r$m or acon'tant eed rate o 20 mm/min
Lor !!==4 !! 0= 00-== r$m
re'ulted in TMT'olidu'
Lor !!6061 the T'olidu' &a' reachedat 1100 r$m &here no &eldin# &a'ormed* !l'o at lo& r$m level' N==r$m
Pa"e 19
!tt:asm/mat.eb/com
!tt:.../$i%a-ortal/or"smas!"et$i%a2:51515>GLL*J01/$f
7llo# 4emeratureKC emerature 4)
775D5> 03 (D
7701 5(3 (5
77D0D5 >DD D50
00 =00 00 00 1100 100 1=00600
6=0
00
=0
800
8=0
00
!! ==!! 0=!! 6061
Tool rotational '$eed (r$m
Peak Tem$erature (C
Soli$us temerature
http://asm.matweb.com/http://asm.matweb.com/
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
20/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
odeling o the non%linear behavior using'8
Elastomers
Ooo'e cro'' linkin# o amor$hou' Ooo'e ,ation o $olymer chain "y the chemical
"ond' re'ult' in hi#hly ela'tic "ehavior a"ove the#la'' tran'ition tem$erature T#9
Elastomers exhibit viscoelastic behavior
Qree$ < 5 the 'tre'' i' held con'tant the 'trainincrea'e'
&ith time*
Jela,ation < 5 the 'train i' held con'tant the'tre''
decrea'e' &ith time*
3i'coela'tic material $ro$ertie' have 'tron#de$endence on
Viscoelastic nature of elastomer
ma"e ref/ Lakes &/S , Viscoelastic materials
Cree an$ reco%er# be!a%ior of elastomer
Stress an$ strain %ersus time lot
Pa"e 20
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
21/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
9iscoelastic models in '8
Reneralied >a,&ellmodel
Standard linear 'olidmodel
Celvin 3oi#t model Pure >a,&ell model
n ure ma
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
22/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
:on linear hyperelastic simulation odamper elastomer
7 !#er or ;reen elastic material is an i$eall# elastic
material/
Stress-strain relations!i $eri%e$ from a
Strain
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
23/34Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
Mney 3ivlin t* parameter mdel >
Onl# a nearl# incomressible %ersion is a%ailable/
*lastic strain ener"# $ensit# is .ritten in terms of t!e t.o in%ariants of
t!e $eformation tensors 14Cel an$ 24Cel an$ t!e elastic %olume ratio
el
Mostl# use$ mo$el $urin" finite element anal#sis/
&elation bet.een t!e Moone# material arameters, s!ear an$ Eoun"Ns
mo$ulus are,
;0 24C10C01
*0 4C10C01
/yperelastic model used in simulation
Material prperties re?uired r tp and ase
dy>
Eoun"Ns mo$ulus
Poissons ratio =ensit#
Material :rperties re?uired r damper>
Moone# &e%lin mo$el arameter C10 Moone# &e%lin mo$el arameter C01 Eoun"Ns mo$ulus Poissons ratio nitial bulk mo$ulus =ensit#
Pa"e 23
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
24/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
ontact ormulations in '8
o sol%e t!e contact roblems t.o t#es of aroac! is use$
7u"mente$ La"ran"ian met!o$
Penalt# Contact Met!o$
Augmented #agrangian methd
+# $efault COMSOL sol%es contact roblem usin" 7LM, in a Se"re"ate$ a#/
n
Contact ressure %ariable
$" ;a $istance bet.een $estination an$ source boun$ar#
Pn Gser $efine$ enalt# factor
:enalty !ntact Methd
!min Minimum element siFe on t!e contact air/
δ Constant enalt# factor o *stimate$ contact ressure; Clearance bet.een t!e arts
n PenaliFe$ contact ressure , Value of enalt# factor in 7LM $oes not affect
t!e accurac# but it influences t!e con%er"ence/
Penalt# contact met!o$ $oes not reuire e
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
25/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
/yperelastic model results showedincreased de.ection level thanviscoelastic model
Viscoelastic mo$el @#erelastic mo$el
Pa"e 25
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
26/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
COMSOL 7P 47lication Pro"rammin" nterface .!ic! is an interface
base$ on a%a, is use$ to $e%elo custom alication base$ on COMSOL
7n initial ;G is built base$ on a mo$el of a simle Q&ectan"ular +lockN,
!a%in" a oint force actin" on t!e e$"e
inal ;G is built base$ on a mo$el of QMec!anical PartN, !a%in" acombination of forces an$ moments actin" on it
@alin-sai Mo$el, a semi-emirical mo$el c!osen base$ on its accurac#
an$ aroriateness, is use$ to $e%elo al"orit!m to calculate Comosite
Material roerties
omposite structures application buildingusing '8
&ef/ Venkates.aran et al/, 201> COMSOL Conference, +an"alore
Pa"e 2
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
27/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
.!ere,
M comosite material mo$ulus E 22, G12 or R23
fiber material mo$ulus E f , Gf or Rf
matri< material mo$ulus E m, Gm, or Rm
@alin-sai euations are t!e !an$# forms of @illNs "eneraliFe$ self-
consistent mo$el results .it! en"ineerin" aro
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
28/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
$@:U $@
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
29/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
$@
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
30/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, PuneS$MU#A$"@ "@ A S$M:#< #"!B
'tress plot in a =
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
31/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
VSG7LH6; M*S@
esh visuali>ation in =
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
32/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune!"@"U3 :#"
ontour stress plot in =
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
33/34
Unrestricted/ © Siemens AG 2015. All rights reservedCOMSOL Conference, 29-30 October, 2015, Pune
The modelin# o riction 'tir &eldin# $roce'' ha' enhancedthe under'tandin# o the $roce'' and re'ulted in reducin#the e,$erimental run'
The 'election o a$$ro$riate model and $arameter' i' thekey in modelin# the non-linear re'$on'e o the $olymeric'tructure
;!3! !P5 o$tion in QU>SUO ena"led the $re and $o't$roce''in# RB5 or com$o'ite 'tructure'H modelin#
oncluding remarks
Pa"e 33
-
8/16/2019 Multi-physics and non-linear modeling using COMSOL
34/34
!uthor thank'<
:ande 3 (Je'earch Rrou$ :eadSiemen' Tech* and Service' Pvt* Otd* +an#aloreor hi' in$ut' a$$roval
Qhethan Javi +JSiemen' Tech* and Service' Pvt* Otd* +an#aloreor hi' contri"ution on vi'coela'tic/hy$erela'ticmodelin# re'ult'
*cknowledgment